Cut pile carpet with color accents and methods of manufacture thereof

ABSTRACT

A multicolored and accented carpet includes a plurality of tufts of color accented fiber including two or more differently colored extruded solution dyed yarns and a base yarn twisted together whereby a plurality of color transitions are provided along the length of the single accented fiber. A cut pile carpet is produced, having the appearance of a space dyed carpet, with the fade and bleach resistance of a solution dyed carpet.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the priority benefit of U.S. Provisional PatentApplication Ser. No. 62/218,797 filed Sep. 15, 2015, the entirety ofwhich is hereby incorporated herein by reference for all purposes.

TECHNICAL FIELD

The present invention relates generally to the field of carpet, and thedesign and manufacturing thereof. The invention relates moreparticularly to cut pile carpet having color accents provided by atri-color solution-dyed yarn, to the multi-color solution dyed carpetyarn, and to methods and processes for manufacture of such carpet andyarn.

BACKGROUND

In residential cut pile carpet applications, color highlights aretypically achieved by the incorporation of yarns that have color accentsapplied in a process known as “space dyeing.” Carpets with color accentsand highlights are growing in popularity as they keep a clean appearancelonger than a solid color carpet. In a typical space dye process, asingle end of yarn is processed through a machine which has a series ofcomputer controlled applicators or jets which apply dye (color) invarious patterns (long and short dots) along the length of the yarn.These color patterns provide color accents when the yarn is tufted intoa carpet. The end of yarn with color accents applied (“spaced dyedyarn”) is twisted with another end of yarn without accents. Thenon-accented yarn can be pre-colored (“solution dyed”) or have nocolorant added (“natural white yarn”). The 2-ply yarn bundle is thenheat set. This process uses steam and heat to impart twist memory to theyarn. The twist is locked in place which allows carpets to haveresistance to foot traffic.

The yarn with colored accents (“space dye”) is then planted with regularnon-accented yarn (“natural yarn or solution dyed”) on a tufting machine(a 12 to 15 foot wide computer controlled high speed sewing machine).The tufting machine then tufts the yarns together in a primary backingto produce the carpet with color accents and highlights. Depending onwhether the non-accented or white “natural” yarns have color added“solution dyed”, additional dyeing and coloring may be necessary afterthe tufts are formed in the primary backing, and before application ofthe secondary backing.

However, space-dyed yarns and other color-additive processes by whichaccents and colors are added to yarns after fiber development are knownto have additional benefits with respect to the carpet's durability,lifespan and overall appearance. Carpets with colored accents providedby “space dyed” yarns are not only aesthetically pleasing, for examplebecause of the multi-colors in the carpet, but they additionally havethe ability to mask soiling and walkout patterns that traditional solidcolor carpets show after years of use in residential homes andapartments. They do however, have a susceptibility to sunlight fadingand can become faded when exposed to harsh cleaning chemicals such ashousehold bleach (sodium hypochloride solutions). Moreover, additionalmanufacturing steps utilized to dye the yarns results in additionalcapital and labor expenses to produce multicolored and accented carpets.

Some carpet fiber manufacturing machines (e.g., extrusion machines) havethe ability to produce a yarn bundle that contains three differentcolors of fiber within the bundle. The extrusion machines are known as“tri-color extrusion machines”. The machines have traditionally beenused to produce fibers utilized in loop pile carpets of the sortprimarily used in commercial applications, but not in the production ofcut pile or tufted carpets of the sort more typically used inresidential applications.

Accordingly, it has been found that needs exist for a non-space-dyedcolor accented and highlighted carpet, to provide the soil and traffichiding capabilities of traditional space dyed accented carpets plus theadditional feature of resistance to sunlight fading and resistance tostrong household cleaners and bleach (sodium hypochloride). It is to theprovision of a cut pile carpet, carpet yarns for producing such carpet,and methods of manufacture and use thereof meeting these and other needsthat the present invention is primarily directed.

SUMMARY

In example embodiments, the present invention provides an extrusion orsolution-dyed multicolored and/or color-accented or highlighted carpet,and manufacturing methods and processes for producing such carpetwithout the use of space-dying processes. The resulting carpet providesthe attractive appearance of space dyed carpets, but having the benefitof the fade resistance and bleach resistance of solution dyed carpets.In further embodiments, the invention provides a carpet yarn having amulti-color solution dyed fiber twisted together with a single ply ofsolid colored fiber. Further embodiments of the invention providemethods of manufacture and use of such carpet and carpet yarn.

In one aspect, the invention relates to a multicolored carpet includinga primary backing material, and a plurality of piles tufted with theprimary backing material to form a carpet. In example forms, at least aportion of the piles of the carpet include color accented 2-ply yarns.In example embodiments, the color accented 2-ply yarns include a singleply tri-colored solution dyed fiber twisted together with a single plyof solid colored fiber. In example embodiments, one or more piles tuftedwith the primary backing material are in the form of solid color 2-plyyarns.

Optionally, one or more piles tufted with the primary backing materialin the form of a barber pole yarn. In example embodiments, the barberpole yarn includes a 2-ply yarn having two differing colors ofpre-colored, solution dyed fibers. In example embodiments, about 10-70%of the piles tufted with the primary backing include color accented2-ply yarns. According to one example embodiment, about 33% of the pilestufted with the primary backing include color accented 2-ply yarns. Inexample embodiments, the color accented 2-ply yarn in combination withthe barber pole yarn provides a plurality of color transitions along alength of the carpet. In one example embodiment, the carpet includes cutpiles. In another example embodiment, the carpet includes a combinationof cut piles and loop piles.

In another aspect, the invention relates to a method of manufacturingmulticolored and color accented carpet including providing a coloraccented 2-ply yarn, providing a primary backing, and tufting the coloraccented 2-ply yarn into the primary backing to form the carpet. Inexample embodiments, the color accented 2-ply yarn includes at least twodifferently colored extruded solution dyed yarns twisted together,wherein twisting of the at least two colored extruded solution dyedyarns results in a plurality of color transitions along a length of thecolor accented 2-ply yarn.

In example embodiments, prior to tufting the color accented 2-ply yarninto the primary backing, the color accented 2-ply yarn is twistedtogether with a main fiber, and wherein twisting of the color accented2-ply yarn about the main fiber provides for a plurality of colortransitions along the length thereof. In one example embodiment, themethod further includes tufting barber pole yarn into at least a portionof the primary backing. In example embodiments, the barber pole yarnincludes a 2-ply yarn having two differing colors of pre-colored,solution dyed fibers. In another example embodiment, the method furtherincludes tufting solid color 2-ply yarns into the primary backing.

In another aspect, the invention relates to a multicolored and coloraccented cut pile carpet including at least one pile in the form ofcolor accented 2-ply yarn, at least one pile in the form of barber poleyarn, and at least one pile in the form of solid color 2-ply yarn. Inexample embodiments, the at least one color accented 2-ply yarn includesa single ply tri-colored solution dyed fiber twisted together with asingle ply of solid colored fiber. In example embodiments, the barberpole yarn includes a 2-ply yarn having two differing colors ofpre-colored, solution dyed fibers. In example embodiments, about 33% ofthe piles comprise the color accented 2-ply yarn.

These and other aspects, features and advantages of the invention willbe understood with reference to the drawing figures and detaileddescription herein, and will be realized by means of the variouselements and combinations particularly pointed out in the appendedclaims. It is to be understood that both the foregoing generaldescription and the following brief description of the drawings anddetailed description of the invention are exemplary and explanatory ofpreferred embodiments of the invention, and are not restrictive of theinvention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The patent or application file contains at least one drawing executed incolor. Copies of this patent or patent application publication withcolor drawing(s) will be provided by the Office upon request and paymentof the necessary fee.

FIG. 1 is a plan view of three colored yarns prior to being twistedtogether to form a single ply accented yarn, according to an exampleembodiment of the present invention.

FIG. 2 is a plan view of the single ply accented yarn formed by twistingthe yarns of FIG. 1 together, according to an example embodiment of thepresent invention.

FIG. 3 is a plan view of the single ply accented yarn of FIG. 2 beingtwisted together with a main fiber to form a 2-ply tri-color accentedyarn, according to an example embodiment of the present invention.

FIG. 4 is a plan view of the resulting 2-ply tri-color accented yarn ofFIG. 3 formed by twisting together the single accented yarn of FIG. 2with a main fiber, according to an example embodiment of the presentinvention.

FIG. 5 is a schematic elevation view of a tufted carpet having piles of2-ply tri-color accented yarns and regular yarns forming a multicoloredand accented carpet according to an example embodiment of the presentinvention.

FIG. 6 is a chart showing ΔE values of a plurality of color combinationsaccording to example embodiments of the present invention.

FIG. 7 shows a perspective view of a of component of a yarn extrusionand twisting machine showing draw rolls of the extrusion machine, whichare provided to stretch the fibers for strengthening.

FIG. 8 is a close up perspective view of a finished package oftri-colored accented fiber according to an example embodiment of thepresent invention.

FIG. 9 is a plan view of a multicolored and accented carpet according toan example embodiment of the present invention.

FIG. 10 is a close up view of the multicolored and accented carpet ofFIG. 9.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

The present invention may be understood more readily by reference to thefollowing detailed description of the invention taken in connection withthe accompanying drawing figures, which form a part of this disclosure.It is to be understood that this invention is not limited to thespecific devices, methods, conditions or parameters described and/orshown herein, and that the terminology used herein is for the purpose ofdescribing particular embodiments by way of example only and is notintended to be limiting of the claimed invention. Any and all patentsand other publications identified in this specification are incorporatedby reference as though fully set forth herein.

Also, as used in the specification including the appended claims, thesingular forms “a,” “an,” and “the” include the plural, and reference toa particular numerical value includes at least that particular value,unless the context clearly dictates otherwise. Ranges may be expressedherein as from “about” or “approximately” one particular value and/or to“about” or “approximately” another particular value. When such a rangeis expressed, another embodiment includes from the one particular valueand/or to the other particular value. Similarly, when values areexpressed as approximations, by use of the antecedent “about,” it willbe understood that the particular value forms another embodiment.

In example embodiments, the present invention generally relates to acolor accented fiber, for example, wherein two or more solution dyedyarns comprising differing colors are twisted together to form a coloraccented fiber. In example forms, the two or more yarns are extrudedusing an extruding machine and each yarn is solution dyed to provide adesired color. In example forms, the extrusion machine may be anOrlicon-Neumag extrusion machine. Optionally, according to other exampleembodiments, other tri-color extrusion machines may be used to form theyarns, for example, a Neumag SD5, Plantex, Impianti, Filteco, Bermag orother tri-color extrusion machines. According to typical example forms,each of the two or more yarns are generally a solid color (which isgenerally different from the other colors of the two or more yarns), andwhereby twisting the yarns together provides a resulting yarn comprisinga plurality of color accents. For example, depending on the colors andtwist of the yarns, the resulting twisted yarn comprises a plurality ofcolor accents or highlights at points or segments along its length, forexample, which is substantially visibly similar to a traditional spacedyed color accented fiber.

With reference now to the drawing figures, wherein like referencenumbers represent corresponding parts throughout the several views,FIGS. 1-4 show a process for forming a 2-ply tri-color accented yarn 22according to an example embodiment of the present invention. In exampleembodiments, about three colored yarns or fibers 10, 12, 14 are twistedtogether to form a single accented yarn 16 (see FIGS. 1-2), and then thesingle accented yarn 16 is then twisted together with an additionalsolid colored yarn or main fiber 20 to form a 2-ply tri-color accentedyarn 22 (see FIG. 4). The solid colored fiber 20 is generally providedwithout accents and can be pre-colored (e.g., solution dyed) or can be anon-colored yard (e.g., a natural white yarn). After the twisting, the2-ply tri-color accented yarn 22 is taken through a heat setting processby which twist memory is provided to the yarn. Alternatively, in otherexample embodiments, only two or more than three colored yarns can betwisted together to form the single multi-color accented yarn, forexample, when more or fewer colors are desired.

According to example forms, the fibers 10, 12, 14 and 16 can be formedfrom one or more materials including polyethylene terephthalate (PET),polytrimethylene terephthalate (PTT), polyamides (nylon 6 or nylon 6,6),polypropylene (PP), olefins or any polymer fiber as desired. Optionally,other natural or synthetic materials (or combinations thereof) may beused as desired.

In example forms, the twist process by which the fibers 16 and 20 aretwisted together results in one of the three colors (of the fibers 10,12, 14) being positioned along the exterior of the 2-ply tri-coloraccented yarn 22 at different segments or positions along the length Lof the yarn (see FIG. 4). In example embodiments, the 2-ply tri-coloraccented yarn 22 comprises a plurality of accents (e.g., colortransitions) along the length L thereof. For example, starting from thetop end of the 2-ply tri-color accented yarn 22, a segment of yarn 10 isvisible, followed by a segment of yarn 14, followed by a segment of yarn12, and so forth along the entire length L of the yarn. In exampleforms, the twist process causes one of the yarns 10, 12, 14 to becomepresent along the exterior thereof randomly by chance, for example,wherein there is generally no set values to control which of the yarns10, 12, 14 will be exposed for a given length of the 2-ply tri-coloraccented yarn 22. However, according to additional example embodiments,one or more parameters may be configured with the twist process suchthat the 2-ply tri-color accented yarn 22 comprises a desired pattern ofcolors, and for example, wherein the span or length of each coloredsegment can be configured as desired.

In example embodiments, prior to forming the carpet, the 2-ply tri-coloraccented yarn 22 is generally planted with regular non-accented yarn 24(e.g., natural yarn or solution dyed yarn) on a tufting machine (e.g.,12-15 foot wide computer controlled high speed sewing machine). In someexample forms, the regular non-accented yarn 24 is in the form of 2-plysolid colored solution dyed yarn. The tufting machine then forms tuftsof the yarn within a primary backing material to form a carpet greigecloth 30 (see FIG. 5). As shown in FIG. 5, the carpet greige cloth 30comprises a plurality of tufts including tufts formed from the 2-plytri-color accented yarn 22 and tufts formed from the regularnon-accented yarn 24. According to preferred forms, the carpet greigecloth 30 is in the form of cut pile carpet. Optionally, the carpetgreige cloth 30 may be in the form of loop pile, or a combination ofboth cut pile and loop pile. According to some example forms, thethread-up configurations for the tufting machine are A-A-A-B or AB AB,for example, where A is the non-accented regular fiber 24 and B is the2-ply tri-color accented yarn 22.

According to example embodiments, the ΔE values (i.e., the colordifference or perceived “distance” between two colors, for exampleaccording to the International Commission on Illumination (CIE) CIELABcolor scale or color space) of the fibers determine the effect of thecolors and their exposure throughout the plurality of tufts formed inthe carpet 30. According to one form, the ΔE values comprise a ΔL value,a Δa value and a Δb value. To provide a preferred effect of thetri-color accents (e.g., a generally high contrast), the ΔL value isabout 50, the Δa value is about 19, and the Δb value is about 19.Optionally, to provide a tonal effect, the Δa and Δb values can be setat about 10. Optionally, the ΔL value, Δa value and Δb value can be setas desired, for example, to provide the desired effect. According toexample forms, for example as depicted in FIG. 6, the ΔE values (ΔL, Δa,and Δb) can be configured to produce a plurality of color combinations.For example, sample A includes three colors including beige, black, andorange. As shown, each of the three colors comprises a ΔE value.According to some example forms, the tolerance level ΔE CMC is generallyset between about 0.5-1.0.

According to some example embodiments, if the regular non-accented fiber24 is a pre-colored solid color (e.g., solution dyed), then the carpetcloth (greige goods) of FIG. 5 has SBR carpet backing applied prior topackaging for shipment. However, if the non-accented regular yarn 24(“natural white yarn”) requires additional color to be applied, thecarpet cloth can be over-dyed with aqueous dyes into the desired colorin the background. The background color is generally a light to mediumneutral shade that is lighter than the color accented fiber, forexample, which will allow the carpet to exhibit color highlights. Oncethe carpet cloth (greige goods) has been dyed, a secondary backing andSBR latex can be applied and the carpet can be packaged and prepared forshipment.

According to example forms, the present invention provides a moreconsistent color blend, and a better quality carpet with contrastingcolor accents, which is more light-fast and color enhanced and providessuperior fade resistance compared to previously known carpetmanufactured using space dye processes. Furthermore, the presentinvention preferably eliminates the space dying step of previously knownmanufacturing processes and thus reduces the costs associated therewith.

According to an alternate example embodiment of the present invention,rather than extruding the colored yarns, twisting the yarns, and thenheat setting the yarns (see FIGS. 1-4), the yarns may go through an airentangling and twist tack process. In another aspect, the color accented2-ply yarn 22 is comprised of two 2-ply tri-colored solution dyedfibers, for example, wherein two single accented yarns 16 are twistedtogether, for example, rather than twisting the single accented yarn 16with the main fiber 20. In example embodiments, these two fibers aretwisted together which creates a plurality of color accents along thelength of the yarn. Optionally, these color accented 2-ply yarns can becombined with a solid color 2-ply yarn. For example, in another aspect,the color accented 2-ply yarn comprising two tri-colored solution dyedfibers is combined with solid colored yarn to produce a color accentedmulti-color carpet.

In example embodiments and as depicted in FIG. 11, a pair of draw rollsof an extrusion machine can be provided to stretch the fibers 10, 12, 14to strengthen them, for example prior to being twisted together to formthe single accented yarn 16. After the fibers 10, 12, 14 are twistedtogether, the single accented yarn 16 is generally rolled up on a spoolto form a finished package 40 of tri-color accented fiber 16, forexample, as depicted in FIG. 8. The finished package 40 is then arrangedto be planted with the regular non-accented yarn 24 on the tuftingmachine, for example, to form the carpet greige cloth 30.

FIG. 9 shows a color accented multi-color carpet 50 according to anexample embodiment of the present invention. In example forms, thecarpet 50 is formed from a combination of 2-ply tri-color accented yarn22 regular non-accented yarn 24. In example embodiments, the carpet 50comprises cut pile, however, in other example embodiments, the carpet 50can comprise loop pile, or a combination of cut pile and loop pile. FIG.10 shows a close up, detailed view of the color accented multi-colorcarpet 50.

In another example embodiment, the present invention relates to methodsor processes of manufacturing multicolored and color accented carpet,and to carpet produced by such methods. In example embodiments, themanufacturing method or process comprises providing a single accentedyarn, the single accented yarn comprising at least two differentlycolored extruded solution dyed yarns and a main yarn twisted together,wherein twisting of the at least two colored extruded solution dyedyarns and the main yarn together results in a plurality of colortransitions along a length of the single accented yarn; and tufting thesingle accented yarn into a primary backing to form a carpet.

In another example embodiment, the invention relates to a method ofmanufacturing multicolored and color accented carpet comprisingproviding a color accented 2-ply yarn, the color accented 2-ply yarncomprising at least two differently colored extruded solution dyed yarnstwisted together, wherein twisting of the at least two colored extrudedsolution dyed yarns results in a plurality of color transitions along alength of the color accented 2-ply yarn; providing a primary backing;and tufting the color accented 2-ply yarn into the primary backing toform the carpet. In some example embodiments, prior to tufting the coloraccented 2-ply yarn into the primary backing, the color accented 2-plyyarn is twisted together with a main fiber, and wherein twisting of thecolor accented 2-ply yarn about the main fiber provides for a pluralityof color transitions along the length thereof.

According to another example embodiment, the invention relates to amulticolored and color accented cut pile carpet comprising at least onepile in the form of a color accented 2-ply yarn, at least one pile inthe form of a barber pole yarn, and at least one pile in the form of asolid color 2-ply yarn. In example embodiments, the at least one coloraccented 2-ply yarn comprises a single ply tri-colored solution dyedfiber twisted together with a single ply of solid colored fiber. Inexample embodiments, the barber pole yarn comprises a 2-ply yarncomprising two differing colors of pre-colored, solution dyed fibers,which are twisted together. In example embodiments, about 33% of thepiles comprise the color accented 2-ply yarn. Optionally, themulticolored and color accented carpet can comprise a combination ofcolor accented 2-ply yarn and solid color 2-ply yarn, or for example,can comprise a combination of color accented 2-ply yarn and barber poleyarn.

While the invention has been described with reference to preferred andexample embodiments, it will be understood by those skilled in the artthat a variety of modifications, additions and deletions are within thescope of the invention, as defined by the following claims.

What is claimed is:
 1. A multicolored carpet comprising: a primarybacking material; and a plurality of piles tufted with the primarybacking material to form a carpet, wherein at least a portion of thepiles of the carpet comprise color accented 2-ply yarns, the coloraccented 2-ply yarns comprising a single ply tri-colored solution dyedfiber twisted together with a single ply of solid colored fiber.
 2. Themulticolored carpet of claim 1, further comprising one or more pilestufted with the primary backing material in the form of solid color2-ply yarns.
 3. The multicolored carpet of claim 1, further comprisingone or more piles tufted with the primary backing material in the formof a barber pole yarn.
 4. The multicolored carpet of claim 3, whereinthe barber pole yarn comprises a 2-ply yarn comprising two differingcolors of pre-colored, solution dyed fibers.
 5. The multicolored carpetof claim 1, wherein between about 10-70% of the piles tufted with theprimary backing comprise color accented 2-ply yarns.
 6. The multicoloredcarpet of claim 5, wherein about 33% of the piles tufted with theprimary backing comprise color accented 2-ply yarns.
 7. The multicoloredcarpet of claim 3, wherein the color accented 2-ply yarn in combinationwith the barber pole yarn provides a plurality of color transitionsalong a length of the carpet.
 8. The multicolored carpet of claim 1,wherein the carpet comprises cut piles.
 9. The multicolored carpet ofclaim 8, wherein the carpet comprises a combination of cut piles andloop piles.
 10. A method of manufacturing multicolored and coloraccented carpet, the method comprising: providing a color accented 2-plyyarn, the color accented 2-ply yarn comprising at least two differentlycolored extruded solution dyed yarns twisted together, wherein twistingof the at least two colored extruded solution dyed yarns results in aplurality of color transitions along a length of the color accented2-ply yarn; providing a primary backing; and tufting the color accented2-ply yarn into the primary backing to form the carpet.
 11. The methodof claim 10, wherein prior to tufting the color accented 2-ply yarn intothe primary backing, the color accented 2-ply yarn is twisted togetherwith a main fiber, and wherein twisting of the color accented 2-ply yarnabout the main fiber provides for a plurality of color transitions alongthe length thereof.
 12. The method of claim 11, further comprisingtufting barber pole yarn into at least a portion of the primary backing.13. The method of claim 12, wherein the barber pole yarn comprises a2-ply yarn comprising two differing colors of pre-colored, solution dyedfibers.
 14. The method of claim 11, further comprising tufting solidcolor 2-ply yarns into the primary backing.
 15. A multicolored and coloraccented carpet formed by the method of claim
 10. 16. The method ofclaim 10, further comprising cutting at least a portion of the piles ofthe carpet.
 17. A multicolored and color accented cut pile carpetcomprising: at least one pile in the form of a color accented 2-plyyarn; at least one pile in the form of a barber pole yarn; and at leastone pile in the form of a solid color 2-ply yarn.
 18. The multicoloredand color accented cut pile of claim 17, wherein the at least one coloraccented 2-ply yarn comprises a single ply tri-colored solution dyedfiber twisted together with a single ply of solid colored fiber.
 19. Themulticolored and color accented cut pile of claim 17, wherein the barberpole yarn comprises a 2-ply yarn comprising two differing colors ofpre-colored, solution dyed fibers.
 20. The multicolored and coloraccented cut pile of claim 17, wherein about 33% of the piles comprisethe color accented 2-ply yarn.